U.S. patent number 8,235,201 [Application Number 12/490,967] was granted by the patent office on 2012-08-07 for flight bar assembly, apparatus and methods for nestable collation of objects.
This patent grant is currently assigned to Illinois Tool Works Inc.. Invention is credited to Gregory Bruns, Mathias Coulomb, John Griffin Miller.
United States Patent |
8,235,201 |
Miller , et al. |
August 7, 2012 |
**Please see images for:
( Certificate of Correction ) ** |
Flight bar assembly, apparatus and methods for nestable collation
of objects
Abstract
Apparatus, flight bar assemblies, and methods are disclosed for
nesting objects into a substantially staggered arrangement. Such
nesting may be done in a nesting zone of a machine, for example,
just upstream of a shrink wrapping machine. The nested arrangement
allows the grouping of nested objects to be shrink-wrapped without
use of trays or cardboard blanks if desired. The flight bar
assemblies may include movable spacers for orienting rows of
objects before, during, and after nesting. Lane dividers may be
provided having lengths corresponding to a contour of an outer
guide and cam surface, cooperating with the lane dividers to
selectively urging the rows of objects inward in an organized
fashion to allow efficient and reliable nesting.
Inventors: |
Miller; John Griffin (Easley,
SC), Bruns; Gregory (Moore, SC), Coulomb; Mathias
(Greenville, SC) |
Assignee: |
Illinois Tool Works Inc.
(Glenview, IL)
|
Family
ID: |
42668937 |
Appl.
No.: |
12/490,967 |
Filed: |
June 24, 2009 |
Prior Publication Data
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|
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Document
Identifier |
Publication Date |
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US 20100326015 A1 |
Dec 30, 2010 |
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Current U.S.
Class: |
198/419.3;
198/418; 53/543 |
Current CPC
Class: |
B65G
47/088 (20130101); B65G 21/2072 (20130101); B65G
2201/0244 (20130101) |
Current International
Class: |
B65G
47/26 (20060101) |
Field of
Search: |
;198/418,418.7,418.8,419.3,429,430 ;53/543 |
References Cited
[Referenced By]
U.S. Patent Documents
Foreign Patent Documents
Other References
International Search Report for PCT/US2010/035372--4 pages. cited
by other.
|
Primary Examiner: Bidwell; James R
Attorney, Agent or Firm: Dority & Manning, P.A.
Claims
What is claimed:
1. An apparatus for nesting objects in a substantially staggered
arrangement, the objects being received from an object feed in a
plurality of groups in substantially parallel rows extending along
a feed direction, the nesting apparatus comprising: a flight bar
drive; a flight bar assembly including a flight bar extending
laterally across the feed direction and driven by the flight bar
drive through a nesting zone in the feed direction, the flight bar
pushing the plurality of groups through the nesting zone, the
flight bar assembly including at least one spacer extending forward
of the flight bar when in the nesting zone for contacting an object
in one of the groups to push the one group forward of others of the
groups, the spacer being slidable laterally along the flight bar as
the flight bar moves through the nesting zone, the spacer
maintaining contact with the object in the one of the groups as the
spacer slides laterally, the spacer having a lateral width
approximately equaling a width of one of the objects, the spacer
extending forward of the flight bar a length approximately equal to
one-half of the width of one of the objects; and at least one guide
extending along one side of the nesting zone, the guide having a
contact surface for moving at least one of the groups of objects
laterally within the nesting zone while the flight bar pushes all
of the groups through the nesting zone, wherein the flight bar, the
spacer on the flight bar, and the guide are configured with respect
to the objects so as to cooperate in nesting the objects into a
substantially staggered arrangement during travel through the
nesting zone.
2. The apparatus of claim 1, wherein the flight bar assembly
includes a spring member for urging the spacer laterally outward
toward the guide.
3. The apparatus of claim 2, wherein the flight bar assembly
includes a cam follower, the cam follower being urged laterally
inward thereby compressing the spring member as the flight bar
moves through the nesting zone.
4. The apparatus of claim 3, wherein the flight bar assembly
further includes a second spacer slidably disposed on the flight
bar laterally between the spacer and the guide, the spring member
being disposed between a central anchor and the spacer and having a
first spring constant, the flight bar assembly further including a
second spring member disposed between the spacer and the second
spacer and having a second spring constant, the spring constant of
the spring and the spring constant of the second spring being
inversely proportional to a distance moved by the respective spacer
and second spacer.
5. The apparatus of claim 4, wherein the cam follower is located on
the second spacer.
6. The apparatus of claim 4, further including a second guide
located opposite the guide, the guide and the second guide having
respective contact surfaces that are nearer each other in a
downstream portion of the nesting zone.
7. The apparatus of claim 1, further including a plurality of lane
dividers extending along the feed direction into the nesting zone,
each lane divider disposed between two of the rows.
8. The apparatus of claim 7, wherein the lane dividers extend to
differing lengths within the nesting zone.
9. The apparatus of claim 8, wherein the lane dividers in a central
portion of the nesting zone extend further than the lane dividers
in lateral portions of the nesting zone.
10. The apparatus of claim 1, further including a dead plate
disposed beneath a substantial portion of the nesting zone.
11. The apparatus of claim 10, further include a plurality of
single-row conveyors disposed upstream of the dead plate for
feeding the objects to the nesting zone and a single nested-group
conveyor disposed downstream of the dead plate for transferring
nested groups of objects from the nesting zone.
12. The apparatus of claim 1, wherein the flight bar and spacer are
cooperatively configured so as to substantially prevent rotation of
the spacer relative to the bar while pushing the objects.
13. The apparatus of claim 12, wherein the flight bar has a
non-circular cross-section.
14. The apparatus of claim 12, wherein the flight bar assembly
includes an orienting bar extending parallel to the flight bar and
through the spacer.
15. A flight bar assembly for a nesting assembly configured for
pushing objects in a feed direction while allowing lateral movement
so as to achieve a staggered nesting pattern, the flight bar
assembly comprising: a flight bar extending laterally across the
feed direction; a plurality of spacers extending in the feed
direction from the flight bar, at least one of the spacers being a
slidable spacer that is laterally slidable along the flight bar,
the spacers having a lateral width less than a width of the one of
the objects, the spacers extending forward of the flight bar a
length approximately equal to one-half of the width of one of the
objects; a least one compression spring for urging the slidable
spacer toward an end of the flight bar and away from a center of
the flight bar; and a cam follower operatively engaged with the
slidable spacer, whereby pushing the cam follower toward the center
of the flight bar slides the slidable spacer toward the center of
the flight bar by compressing the compression spring member.
16. The flight bar assembly of claim 15, wherein centers of the
spacers are disposed a first distance apart when the compression
spring is in a default position and a smaller second distance apart
when the compression spring is moved inward by the cam
follower.
17. The flight bar assembly of claim 16, wherein the first distance
corresponds to two times the width of one the objects and the
second distance corresponds to less than two times the width of the
one of the objects.
18. The flight bar assembly of claim 17, wherein the second
distance corresponds to the lateral distance between the centers of
three rows of the objects nested hexagonally.
19. The flight bar assembly of claim 15, wherein the flight bar and
spacers are cooperatively configured so as to substantially prevent
rotation of the spacers relative to the bar while pushing the
objects.
20. The flight bar assembly of claim 19, wherein the flight bar has
a non-circular cross-section.
21. The flight bar assembly of claim 19, wherein the flight bar
assembly includes an orienting bar extending parallel to the flight
bar and through the spacer.
22. The flight bar assembly of claim 15, wherein a second one of
the spacers is also slidable, the second spacer slidably disposed
on the flight bar laterally between the spacer and the guide, the
compression spring being disposed between a central anchor and the
spacer and having a first spring constant, the flight bar assembly
further including a second spring member disposed between the
spacer and the second spacer and having a second spring constant,
the spring constant of the spring member and the spring constant of
the second spring member being inversely proportional to a distance
moved by the respective spacer and second spacer.
23. A method of nesting objects comprising: feeding objects in a
feed direction in plurality of rows into a nesting zone;
selectively maintaining separation of the rows via lane dividers
between the rows, the lane dividers having differing lengths
extending into the nesting zone; pushing the rows of objects into
the nesting zone using a flight bar assembly, the flight bar
assembly having a flight bar and spacers extending forward from the
flight bar in the feed direction, at least one of the spacers being
a slidable spacer that is laterally slidable along the flight bar,
the spacers having a lateral width less than a width of the one of
the objects, the spacers extending forward of the flight bar a
length approximately equal to one-half of the width of one of the
objects, the spacers arranged to contact and push every other row
of the objects with a row of the objects in between; and sliding at
least some of the spacers laterally inward relative to the flight
bar while in the nesting zone as the rows of objects exit the lane
dividers while urging the outermost rows of objects inward to
achieve a staggered nested arrangement of objects.
Description
TECHNICAL FIELD
The present disclosure relates to flight bar assemblies, apparatus
and methods for nestably collating objects.
BACKGROUND
Various methods and devices have been proposed for grouping and
holding objects such as containers for shipping. For example,
paperboard or cardboard cartons, boxes and trays, stretch wrapping
and shrink wrapping, as well as combinations of the above have been
employed. Various types of machines have been developed to feed,
group, and package such containers.
When shrink wrapping is employed, often objects are grouped on a
cardboard tray having folded up edges before applications and
shrinking of the shrink film. Such trays are employed to provide
stability during loading, shrink wrapping and shipment. Trays are
typically rectangular, with four folded-up sides to. The edges are
typically glued and/or stapled to hold them in the desired form.
The articles, if all of the same type, are typically arranged in a
grid on the tray. Twenty-four bottles could be arranged in a
4.times.6 grid on a tray, for example. Alternatively, blanks in the
form of rectangular sheets of cardboard (without the folded up
edges) have also been used to provide similar benefits.
Such packaging while generally effective has certain drawbacks. For
example, using cardboard and shrink film requires more raw
materials and resources than using either alone, and requires
complicated machinery to organize and assemble a shrink-wrapped
package of objects. Also, at times it can be difficult to create
machinery that allows for flexibility in packaging of objects in
different configurations and or groupings. That is, major changes
have been required in order to change a packaging line if a change
in product or grouping is desired. Also, use of such trays and
blanks typically results in only an orthogonal grid arrangement
matching the dimensions of the trays and blanks. In such
arrangements, inherently due to the grid organization, interior
objects may contact directly only four adjacent objects.
Accordingly, there remains a need for improved flight bar
assemblies, apparatus and methods for collation of objects.
SUMMARY
In accordance with some aspects of the present subject matter, an
apparatus is disclosed for nesting objects in a substantially
staggered arrangement, the objects being received from an object
feed in a plurality of groups in substantially parallel rows
extending along a feed direction, the nesting apparatus including a
flight bar drive, a flight bar assembly including a flight bar
extending laterally across the feed direction and driven by the
flight bar drive through a nesting zone in the feed direction, the
flight bar pushing the plurality of groups through the nesting
zone, the flight bar assembly including at least one spacer
extending forward of the flight bar when in the nesting zone for
contacting an object in one of the groups to push the one group
forward of others of the groups, the spacer being slidable
laterally along the flight bar as the flight bar moves through the
nesting zone, the spacer maintaining contact with the object in the
one of the groups as the spacer slides laterally, the spacer having
a lateral width approximately equaling a width of one of the
objects, the spacer extending forward of the flight bar a length
approximately equal to one-half of the width of one of the objects,
and at least one guide extending along one side of the nesting
zone, the guide having a contact surface for moving at least one of
the groups of objects laterally within the nesting zone while the
flight bar pushes all of the groups through the nesting zone,
wherein the flight bar, the spacer on the flight bar, and the guide
are configured with respect to the objects so as to cooperate in
nesting the objects into a substantially staggered arrangement
during travel through the nesting zone. Various options and
modifications are possible.
For example, the flight bar assembly may include a spring member
for urging the spacer laterally outward toward the guide, and may
also include a cam follower, the cam follower being urged laterally
inward thereby compressing the spring member as the flight bar
moves through the nesting zone. The flight bar assembly may further
include a second spacer slidably disposed on the flight bar
laterally between the spacer and the guide, the spring member being
disposed between a central anchor and the spacer and having a first
spring constant, the flight bar assembly further including a second
spring member disposed between the spacer and the second spacer and
having a second spring constant, the spring constant of the spring
and the spring constant of the second spring being inversely
proportional to a distance moved by the respective spacer and
second spacer. If desired, the cam follower may be located on the
second spacer. Also, a second guide may be located opposite the
guide, the guide and the second guide having respective contact
surfaces that are nearer each other in a downstream portion of the
nesting zone.
A plurality of lane dividers may extend along the feed direction
into the nesting zone, each lane divider disposed between two of
the rows. If desired, the lane dividers may extend to differing
lengths within the nesting zone. For example, the lane dividers in
a central portion of the nesting zone may extend further than the
lane dividers in lateral portions of the nesting zone.
A dead plate may be disposed beneath a substantial portion of the
nesting zone, and a plurality of single-row conveyors may be
disposed upstream of the dead plate for feeding the objects to the
nesting zone and a single nested-group conveyor disposed downstream
of the dead plate for transferring nested groups of objects from
the nesting zone.
The flight bar and spacer may be cooperatively configured so as to
substantially prevent rotation of the spacer relative to the bar
while pushing the objects. For example, the flight bar may have a
non-circular cross-section, or the flight bar assembly may include
an orienting bar extending parallel to the flight bar and through
the spacer.
According to other aspects of the disclosure, a flight bar assembly
is disclosed for a nesting assembly configured for pushing objects
in a feed direction while allowing lateral movement so as to
achieve a staggered nesting pattern, the flight bar assembly
including a flight bar extending laterally across the feed
direction, a plurality of spacers extending in the feed direction
from the flight bar, at least one of the spacers being a slidable
spacer that is laterally slidable along the flight bar, the spacers
having a lateral width less than a width of the one of the objects,
the spacers extending forward of the flight bar a length
approximately equal to one-half of the width of one of the objects,
a least one compression spring for urging the slidable spacer
toward an end of the flight bar and away from a center of the
flight bar, and a cam follower operatively engaged with the
slidable spacer, whereby pushing the cam follower toward the center
of the flight bar slides the slidable spacer toward the center of
the flight bar by compressing the compression spring member. Again,
various options and modifications are possible.
For example, the centers of the spacers may be disposed a first
distance apart when the compression spring is in a default position
and a smaller second distance apart when the compression spring is
moved inward by the cam follower, and the first distance may
correspond to two times the width of one the objects and the second
distance corresponds to less than two times the width of the one of
the objects. Also, the second distance may correspond to the
lateral distance between the centers of three rows of the objects
nested hexagonally.
The flight bar and spacers may be cooperatively configured so as to
substantially prevent rotation of the spacers relative to the bar
while pushing the objects. As such, the flight bar may have a
non-circular cross-section, or the flight bar assembly may include
an orienting bar extending parallel to the flight bar and through
the spacer.
If desired, a second one of the spacers may also be slidable, the
second spacer slidably disposed on the flight bar laterally between
the spacer and the guide, the compression spring being disposed
between a central anchor and the spacer and having a first spring
constant, the flight bar assembly further including a second spring
member disposed between the spacer and the second spacer and having
a second spring constant, the spring constant of the spring member
and the spring constant of the second spring member being inversely
proportional to a distance moved by the respective spacer and
second spacer.
According to other aspects of the disclosure, a method of nesting
objects includes feeding objects in a feed direction in plurality
of rows into a nesting zone; selectively maintaining separation of
the rows via a lane dividers between the rows, the lane dividers
having differing lengths extending into the nesting zone; pushing
the rows of objects into the nesting zone using a flight bar
assembly, the flight bar assembly having a flight bar and spacers
extending forward from the flight bar in the feed direction, at
least one of the spacers being a slidable spacer that is laterally
slidable along the flight bar, the spacers having a lateral width
less than a width of the one of the objects, the spacers extending
forward of the flight bar a length approximately equal to one-half
of the width of one of the objects, the spacers arranged to contact
and push every other row of the objects with a row of the objects
in between; and sliding at least some of the spacers laterally
inward relative to the flight bar while in the nesting zone as the
rows of objects exit the lane dividers while urging the outermost
rows of objects inward to achieve a staggered nested arrangement of
objects. Again, various options and modifications are possible.
BRIEF DESCRIPTION OF THE DRAWINGS
A full and enabling disclosure including the best mode of
practicing the appended claims and directed to one of ordinary
skill in the art is set forth more particularly in the remainder of
the specification. The specification makes reference to the
appended figures, in which:
FIG. 1 is a perspective view of an upstream portion of a nesting
assembly;
FIG. 2 is a perspective view of a downstream portion of the nesting
assembly of FIG. 1;
FIG. 3 is a top view of one possible flight bar assembly for a
nesting assembly;
FIG. 4 is front view of the flight bar assembly of FIG. 3;
FIG. 5 is an end view of the flight bar assembly of FIG. 3;
FIG. 6 is a perspective view of on possible lane divider
arrangement for a nesting assembly;
FIG. 7 is a top schematic view of the progression of objects as
being nested in a nesting zone of a nesting assembly;
FIGS. 8A through 8G are close up top diagrammatical views of
objects showing the nesting process;
FIG. 9 is a perspective view showing an example of a shrink-wrapped
package including nested objects;
FIG. 10 is a top view of another possible flight bar assembly;
FIG. 11 is a perspective view of the flight bar assembly of FIG.
10;
FIG. 12 is a top view of another possible flight bar assembly;
FIG. 13 is a top view showing one possible nesting assembly using
the flight bar assembly of FIG. 10; and
FIG. 14 is a top view showing one possible nesting assembly using
the flight bar assembly of FIG. 12.
Use of like reference numerals in different features is intended to
illustrate like or analogous components.
DETAILED DESCRIPTION
Reference will now be made in detail to various and alternative
exemplary embodiments and to the accompanying drawings, with like
numerals representing substantially identical structural elements.
Each example is provided by way of explanation, and not as a
limitation. In fact, it will be apparent to those skilled in the
art that modifications and variations can be made without departing
from the scope or spirit of the disclosure and claims. For
instance, features illustrated or described as part of one
embodiment may be used on another embodiment to yield a still
further embodiment. Thus, it is intended that the present
disclosure includes modifications and variations as come within the
scope of the appended claims and their equivalents.
The present disclosure is generally directed to apparatus, flight
bar assemblies, and methods for nesting objects such as containers
into a substantially staggered arrangement. The nested arrangement
may be in a symmetrical honeycomb or hexagonal relationship or
something else. Such nesting may be done in a nesting zone of a
machine, for example, just upstream of a shrink wrapping machine.
The nested arrangement allows the grouping of nested objects to be
shrink-wrapped without use of trays or cardboard blanks, if
desired. The flight bar assemblies may include movable spacers for
orienting rows of objects before, during, and after nesting. Lane
dividers may be provided having lengths corresponding to a contour
of an outer guide and cam surface, cooperating with the lane
dividers to selectively urge the rows of objects inward in an
organized fashion to allow efficient and reliable nesting.
FIGS. 1 and 2 show an apparatus 100 for receiving a plurality of
rows of objects 102 such as containers and nesting them along a
feed direction F within a nesting zone 104. The rows are defined by
upstream dividers 106 which are adjustably positioned along a
positioning bar 108 by conventional clamps. FIG. 1 shows eight rows
110 between nine dividers 106, but it should be understood that
various numbers and widths may be employed. In fact, if the
apparatus is set up for eight rows, all rows need not be used
(without modification of the apparatus) if fewer rows are desired
in a resulting nested package. Rows 110 are fed by individual
conveyors 112 (see FIG. 7) that lead to a dead plate 114 in nesting
zone 104. If desired dead plate 114 could be a moving conveyor or
could be modified, for example with rollers, air jets, etc.
Frame 116 of apparatus 110 also supports a drive 118 (a
conventional electric motor gearing, etc.) for moving flight bar
assemblies 120 through nesting zone 104. As shown, flight bar
assemblies 120 are mounted on two chains 122 on either side of
nesting zone 104 driven by drive 118. Upstream dividers 106 include
a contoured edge 124 and chains 122 follow a path allowing flight
bar assemblies 120 to drop down to contact the objects at the
beginning of the nesting process.
Side guides 126 are provided in nesting zone 104 to assist in
moving the objects into a nested configuration. The assistance may
be provided by contact with the objects and/or by movement of
slidable portions of the flight bar assemblies 120. Guides 126
include contact surfaces 128 that taper inwardly toward each other
along feed direction F. Downstream ends 132 of guides 126 extend
first upwardly then outwardly so that compressed portions of flight
bar assemblies 120 may be released smoothly without interfering
with the objects after nesting and as so as to follow chains 122.
Guides 126 are laterally adjustable via conventional mounting
hardware 134 so as to define a width of nesting zone 104, including
defining the number of active rows used. Downstream of nesting zone
104 is a conveyor 136 leading to a further station 130, such as a
shrink wrap station.
FIGS. 3-5 show one example of a flight bar assembly 120 including a
flight bar 138 and a number of spacers 140, 142, 144, 146 having
openings 148 for receiving the flight bar. Outer spacers 140 and
146 include cam followers 150. Structure is provided to keep the
spacers from rotating on flight bar 138, in this case a second
orienting bar 152 extending through openings 154 in the spacers.
Both bars 138 and 152 are attached at their ends to chains 122 in a
conventional way so as to be drivable by the chains while
maintaining a front-back orientation.
First spring members 156 are provided between an anchor 158 and
spacers 142 and 144. If desired a single spring member could be
used here. Spring members 156 may be conventional compression
springs. Spacers 142 and 144 may move inwardly by compressing
spring members 156 until stop portions 160 are reached at a
preselected distance corresponding to the width of the objects
102.
Second spring members 162 are provided laterally outward of first
spring members 156 between spacer pairs 140 and 142, and 144 and
146. Accordingly, if cam followers 150 are moved inwardly by a cam
surface such as surfaces 128 of guides 126, then all springs shown
are compressed and all sliders shown are moved inward. Preferably,
inner spacers 142 and 144 move inward until contacting stops 160
and outer spacers 140 and 146 move a correspondingly greater
amount, as will be described below. Also, the spring constants of
the springs can be selected so that either the first or second
springs compress first and/or more once cam followers 150 are moved
inward, as will be discussed below. Also, it should be understood
that various modifications in the number and dimension of spacers
and placement of the springs may be employed depending on the
desired nested package configuration, number and size of objects,
etc.
FIG. 6 shows lane dividers 164-180 that could be used for an eight
or ten row 110 system. As shown, the length of the dividers
increases from both outer dividers 164 and 180 toward central
divider 172. As discussed below, such arrangement allows for
nesting of outer rows first within the nesting zone, as objects can
begin nesting with adjacent rows once passing the end of an
intervening lane divider. Accordingly, by selecting an arrangement
of lengths of the lane dividers in combination with the contour of
the outer guide surfaces 128, an organized and reliably
reproducible nesting of rows can be accomplished. Lane dividers
164-180 may or may not be unitary with the upstream dividers. The
down stream ends of the lane divides may also extend distally so as
to allow lateral flexing during nesting. If desired, lane dividers
164-180 may be individually removable and replaceable to suit a
given package configuration. Alternate dividers may be provided in
a kit, as well as alternate side guides, so as to provide even more
flexibility.
Some of the lane dividers can include slots 182 to allow for use of
a sensor system 184, such as a conventional optical system to note
when a group or articles reaches that point. The sensor system can
be used to trigger other parts of the system, such as an upstream
or downstream conveyor, shrink-wrapping assembly, etc. Thus, once a
substantially nested group of objects passes sensor system 184, it
may be desirable to begin feeding a sheet 186 for wrapping the
group. Such sensors could be other types and could be located at
other places as well. The sensors 184 may be in communication with
a conventional programmable logic controller (PLC) 188, which can
also control and receive input from all parts of the device and
upstream and downstream devices as well.
FIG. 7 shows and overview of four groups A-D of objects passing
though nesting zone 104 from seven (not eight) rows 110. As shown,
each row includes a desired number of objects 102. The number of
objects in each row can be controlled upstream of nesting zone by
conventional flow separation devices, such as movable knife, pin or
bar devices. The number of objects in each row may be identical, or
different (as shown).
Group A is still on conveyors 112 and being moved by the conveyors.
Flight bar assembly 120a is moving in to contact group A. Spacers
140-146 extend along four of the lanes, with interleaved lanes
having no spacer. The flight bars 120 move faster than the groups
so that the flight bars catch and push the groups into the nesting
zone 104.
Group B is being pushed by flight bar 120b. Spacers 140-146 are
pushing objects 102 in their respective rows forward by
approximately one-half of the width of an object. Lane dividers
164-180 (no spacer 172 here) are still keeping the individual rows
separated.
Group C is being nested. Most objects 102 have passed their
respective lane dividers. Cam followers 150 and outer objects 102
are being urged inwardly by surfaces 128. Spring members 156 and
162 are compressing moving in the spacers, more laterally outwardly
than inwardly.
Group D is nested and is leaving the nesting zone 104 and dead
plate 114 for downstream conveyor 136. Spring members 156 are fully
compressed and spacers are in their final position. Flight bar 120d
is about to rise, releasing the spring members and returning the
spacers to the position of Group A. Flight bar 120d will then be
driven on chains 122 to repeat the process.
Note that spacers 140-146 should initially be spaced so that they
are aligned with appropriate rows, taking into account object
thickness and lane divider thickness. Preferably, spacers should
have a width laterally slightly less than that of the objects so
that no pinching occurs during nesting. When nested, centers of
objects two rows apart are less than two object widths apart.
Therefore, when in position of Group D, the centers of adjacent
spacers should have such spacing as well.
FIGS. 8A though 8G show more details of the nesting process shown
in FIG. 7. As illustrated, nesting staggered rows on each side one
at a time (compare 8C, 8D and 8F) from the outside in provides a
reliable nesting method. By making spacers 140-146 movable, the
reliability is improved through the nesting zone.
FIG. 9 shows a resulting package 188 wrapped by sheet 186. No
limitation as to the type of sheet or other holding member should
be assumed. Therefore, the present nesting disclosure could be used
for various purposes, such as palletizing, box loading, tray
loading etc. However, such nesting in a staggered, hexagonal and/or
honeycomb shape does provide improved stability to a group of
articles as compared to a typical orthogonal "grid" grouping. As
shown, objects in a nested arrangement typically contact more
objects in more directions than in an orthogonal arrangement.
Therefore, a package 188 may not need a sheet or tray beneath the
objects for support. Also, alterative groupings and novel package
shapes can be employed by simply positioning a nested number of
objects and wrapping them.
The remaining figures show further options, where like or identical
reference numerals are used on like or identical elements. FIGS. 10
and 11 show an alternate flight bar assembly 220, including a
non-circular, in this case hexagonal, flight bar 238. The openings
in spacers 240-246 can be configured to cooperate with flight bar
238 to prevent rotation of the spacers, thereby avoiding a second
orienting bar as above. Otherwise, operation and configuration of
flight bar assembly 220 is substantially similar to those
above.
FIG. 12 shows a modified flight bar assembly 320, having only three
spacers 340-344. In this case, middle spacer 342 could be fixed,
eliminating the need for an anchor. Also, only two spring members
356 are needed. Flight bar assembly 330 could be used where a
different or a narrower packaging is desired having a differing
arrangement or fewer rows. It should be understood that the
concepts of this disclosure can be used on packages have many fewer
or more rows than those disclosed, as desired to suit a particular
application.
FIGS. 13 and 14 show uses of flight bar assemblies 220 and 320
respectively for different package grouping configurations. As
shown in FIG. 13, seven lanes are used, with an alternating
three/four object grouping. As shown in FIG. 14, seven lanes are
used with constant five object grouping. Note that the left most
row 110a is not used and the left most lane divider 180 has been
moved over one spot to take the place of divider 178 in each
arrangement to allow for smooth nesting without pinching in the
nesting zones. Also, the left side guide 126 has been moved over
one lane as well. Use of movable or changeable lane dividers and
side guides allows for great flexibility in achieving a desired
grouping within minimal expense, effort and down time.
Accordingly, a method of using various of the above structures or
others to package is also encompassed by this disclosure. Such a
method of nesting may include feeding objects 102 in a feed
direction F in plurality of rows 110 into a nesting zone 104. The
method can be carried out by selectively maintaining separation of
the rows 110 via lane dividers 164-180 between the rows. The
various lane dividers may have differing lengths extending into the
nesting zone 104. The method can include pushing the rows of
objects into the nesting zone using a flight bar assembly 120,
etc., including a flight bar and spacers extending forward from the
flight bar in the feed direction. At least one of the spacers can
be a slidable spacer that is laterally slidable along the flight
bar. The spacers have a lateral width less than a width of the one
of the objects and extend forward of the flight bar a length
approximately equal to one one-half of the width of one of the
objects. The spacers are arranged to contact and push every other
row 110 of the objects with another row of the objects in between.
The method can further include sliding at least some of the spacers
laterally inward relative to the flight bar while in the nesting
zone 104 as the rows of objects exit the lane dividers while also
urging the outermost rows of objects inward to achieve a
hexagonally nested arrangement of objects.
Again, use of the term "hexagonally" should not be considered
limiting. As shown, the objects are spaced at 60 degree angles in a
honeycomb or staggered position. This assumes that the objects are
symmetrical and perhaps circular. Differently shaped articles may
not align in a perfect "hexagonal" arrangement, although they could
be staggered and efficiently nested. Further mixing different sizes
of articles in a nested group might not achieve a perfect hexagonal
arrangement either, yet still achieve an acceptable package.
Finally, even with symmetrical circular objects, any other
arrangements achievable though the geometry of the objects and
non-orthogonal would be within the scope of the invention if
nested.
It is appreciated by persons skilled in the art that what has been
particularly shown and described above is not meant to be limiting,
but instead serves to show and teach various exemplary
implementations of the present subject matter. As set forth in the
attached claims, the scope of the present invention includes both
combinations and sub-combinations of various features discussed
herein, along with such variations and modifications as would occur
to a person of skill in the art.
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